Morbark
Ford 6.2 Engine
Post Production Modification
(PPM-103)

Note: Make sure you read and

understand these instructions
before performing the procedure. If
you are confused or uncertain about
the contents of this document,
contact your local dealer or Morbark
directly at 800-255-8839.

Publish Date: 03/29/2022
Last Revised: 12/7/2022
Created by: AB/KB
Total Pages: 10
PPM#

103

Overview
This document describes the steps required to identify what modifications are required
to your specific machine to remedy any instances of engine overheating and include the
following:
•

Replace current radiator (debris) screen with Assembly #40888-451S

•

ECM replace or update

•

Replace rear and top engine enclosure panels if thermal insulation is present.

•

Adjust exhaust tube “Y-Pipe” for clearance to firewall (Note: Replace U bolt
clamps with Morbark PN: 29323-598 as required)

•

Purge cooling system to remove any trapped air

•

Replace radiator fan if existing fan exhausts air from engine assembly instead of
“pulling” air INTO engine assembly.

•

Inspect for faulty Catalytic Converter; replace as necessary.

Affected Machines
NOTE: Some of these modifications may have been previously completed. Please
carefully inspect components prior to replacement.
•

Any of these models that use the Ford 6.2L engine: EB 1821 (Pre
Ser# 26469), EB 1922 (Pre Ser# 52783), EB 2131

Verify and Obtain Parts from this List
Note: Not all of these parts will be required to upgrade your machine. Inspect your
machine and create a checklist of all parts that need to be ordered for your machine.
Place an “X” if associated item(s) apply

Assy/Part No.

Order if existing panel HAS thermal insulation. 40780-451
Order if existing panel HAS thermal insulation. 30501-451
Order if existing exhaust clamps are “U Bolt”
type
Order if existing fan is configured to pull air
AWAY from engine instead of INTO engine
assembly (see Note 1)
Order if Debris Screen has 1/8” dia holes
Order to assist with radiator air purge.
Order if Catalytic Converter is faulty

29323-598
29119-013
40888-451S
29119-061
29119-006

Note 1: Refer to Appendix at back for fan identification photos.

Description: Qty:

Rear Panel

1

Top Panel
Clamp,
Exhaust

1

Fan, Puller
Debris
Screen,
Hinged
Gates Hose
Catalytic
Converter

3
1
1
1
1

Contact Morbark Service at 800-255-8839 if you have ANY questions or need clarification.
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PPM-103

Safety
Dangers, Warnings and Cautions

A Danger explains hazards that will result in personal injury or
death.

A Warning explains hazards that might result in personal
injury or death.

A Caution explains hazards that could cause damage to
equipment and/or machinery.

Personal Protective Equipment (PPE)
For your safety, always adhere to the following guidelines when performing this
procedure:
•

Always wear personal protective equipment (hard hat, safety
goggles/weld mask, work/weld gloves, hearing protection, etc.)
when working on this equipment.

•

Know and avoid pinch/ crush points.

•

Clean all oil spills, and debris around work area to reduce the risk
of slips, trips and falls.

•

If lifting or leveraging equipment and/or assemblies always make
sure all ramps, hoists, lift straps/chains, jacks, jack stands, etc., are
rated and approved for the weights being carried/lifted.

Note – Radiator Care
Please DO NOT use high pressure sprayer to clean radiator. Using a pressure
washer to clean the radiator could result in impacted debris in-between
radiator fins. Impaction can cause loss of airflow, and subsequent exacerbated
overheating. Use compressed air to clean debris from radiator.

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PPM-103

Engine Modification Procedure
1) See Figure 1. Remove the Debris Screen (1), Access Panel (2), Engine Air Intake
Assembly (3), Exhaust Heat Shield (4), Muffler Assembly (5), Rear Panel (6) and
the hardware used to hold the Radiator Cover Plate sides and Engine Lifting Lugs
(highlighted in red circles) on both sides of engine (7) in the order as numbered and
set aside.

6

4

3

5

1
2

7

Figure 1

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PPM-103

2) See Figure 2. Remove Exhaust Pipe (1), Engine Enclosure Top (2) and Chimney
Weldment (3) in the order as numbered and set aside.

2

3
1

Figure 2

3) See Figure 3. Assemble new Chimney Weldment (1), Engine Enclosure Top (2)
and existing Exhaust Pipe (3) in the order as numbered using existing hardware.
Note: See Figure 4 (next page) for exhaust pipe details before installing.

2 (Part #30501-451)

1 (Part #40780-451)
3

Figure 3
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PPM-103

NOTES:
•
•
•

•
•

When changing the fans, adjust the exhaust Y-pipe so it is straight up and down.
This component was clamped to the firewall but this allowed too much heat to
pass through the firewall.
Loosen the exhaust manifold joints and pull the pipe back away from the fire wall
and re-torque.
The Catalyst assembly can be adjusted forward and back to allow better fitment
of the 90 degree exhaust elbow. Here are some pictures of what it should look
like.
Also remind anyone running a Ford 6.2 liter to only use 5w-30 motor oil. Using
a thicker oil with a higher winter weight (10w, 15w) in the winter may cause
timing chain damage.
Double check that all wiring harnesses are tied back away from any heat
sources like the exhaust manifolds.

NOTE: Do NOT reuse U bolt
clamps when re-installing Ypipe.
Make sure pipe is aligned so
that there is even clearance
between pipe and chimney
weldment as shown.

Use 3” band clamp.
Make sure elbow is
fully seated and
there are no leaks at
slots.

Figure 4
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PPM-103

4) See Figure 5. Re-install Rear Panel using existing hardware.

Figure 5

5) See Figure 6. Re-install Muffler Assembly, Access Panel, and Engine Air Intake
Assembly using existing hardware.

Figure 6
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PPM-103

6) See Figure 7. Install new side plates using provided hardware.

Figure 7

7) See Figure 8. Install new debris screen by sliding it onto hinges and fastening with
rubber latches.

Figure 8
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PPM-103

Update or Replace ECM
To update existing ECM contact Art Wicks EDI Service Manager ([email protected]).
This will protect the engine from overheating.
NOTE: Verify calibration prior to updating as all machines may not be affected.
•

Calibration: 5380R35D_GAS_TSC1_1200-3200

Or, to replace ECM do the following:
1)

See Figure 7. Remove screws.

2)

Disconnect wire harnesses.

3)

Remove ECM.

4)

Install new ECM in reverse.

Figure 7
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PPM-103

Purging Air from Radiator Coolant
Note: You can drain and vacuum fill the system or use the following procedure, which would
require a spill-free funnel. (See links below)
Cooling system purge:
https://www.lislecorp.com/specialty-tools/spill-free-funnel-606Lisle 24680 Spill-Free Funnel
[IMPROVED]
1)

Install Gates hose (29119-061) on the inlet and outlet of the water pump.
Remove side panel of engine enclosure. Openings of both hoses should be
visible slightly above and behind the header of the 6.2L Ford engine (See Figure
8).

Figure 8
2)

Using correct adaptor insert funnel into radiator.

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PPM-103

Figure 9

3)

Add fluid coolant (USE: Peak Cool 50/50 Pre-diluted Extended Life anti-freeze
and coolant, 150,000 mile protection, or equivalent that meets or exceeds
WSS-M97B51-A1, ASTM D3306). NOTE: Make sure the funnel is no more than
one-third full to avoid overflow when engine heats up.

4)

Start engine. Let engine idle until engine temperature reaches 205°F. Trapped
air will escape through funnel.

Figure 10

5) Shut down the engine and let cool.
6) Repeat Steps 3 and 4 up to four times to cycle air out.

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PPM-103

7) Squeeze radiator hose then insert the stopper. Remove funnel and install radiator
cap.

Figure 11

8) Transfer remaining coolant to reservoir.

Figure 12

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PPM-103

Inspecting Catalytic Converter
1) Remove exhaust pipe from Catalytic Converter.

2) See figure below. Use a tape measure to see if Catalytic Converter substrate has
shifted; the measurement should be no LESS than 11 inches, and NO MORE than
12 inches. If the substrate is outside of these defined limits it must be replaced.

CORRECT Catalyst Depth

Page 12

INCORRECT Catalyst Depth

PPM-103

3) As well as measuring depth, checking the serial number of the Catalytic Converter
can be used to deduce whether the Catalyst substrate may be at risk of shifting in
the future. Etched onto the label along the outer skin of the main housing is the
Serial Number of each unit. Post Serial Number 415501 Units are less likely to shift
during use. Pre-Serial Number 415501 are more likely to shift and should be
replaced.

Appendix - Fan Identification/Verification

Wrong fan – Arrow points to right.
Replace with correct fan

Page 13

Correct fan – Arrow points to left.

PPM-103